Wind Power Manufacturing Project Using Submerged Arc Welding (SAW) Method

This project focuses on the production and assembly of wind turbine towers through a high-tech process that ensures maximum quality and durability. The process is carried out in several detailed stages, from material preparation to the completion of the final product.

Stage 1: Preparation and Mechanical Processing
Each wind tower is fabricated from steel plates with thicknesses ranging from 15 mm to 80 mm. These plates are precisely cut using CNC machines to achieve the required shapes. They are then rolled into circular sections and longitudinally welded together. This process requires high accuracy to ensure perfect alignment of the joints, resulting in strong and reliable tower segments.

Stage 2: Welding and Assembly
This is the most critical stage, determining the overall quality of the wind tower. The tower segments are joined using the Submerged Arc Welding (SAW) technique with welding equipment supplied by Miller. This method ensures deep penetration, uniformity, and strength of the welds. After welding, all joints are inspected using Non-Destructive Testing (NDT) methods, such as ultrasonic testing, to detect even the smallest defects.

Stage 3: Shot Blasting and Painting
To protect the tower against corrosion and environmental impacts, its surface is cleaned by shot blasting. The tower is then coated with three specialized layers of paint: a primer for anti-rust protection, an intermediate coat, and a final topcoat. The finishing coat not only enhances durability but also provides an aesthetic appearance.

Stage 4: Completion and Installation
After painting, the wind tower is fitted with electrical systems and accessories such as climbing ladders, lighting, and lightning protection systems. All components undergo thorough inspections before being transported to the construction site for final installation.